Define Measure

ControlAnalyze

Reduction in Secondary Packaging costs storyboard – Robert Caldwell

Scope and goals for the project defined in the charter

Improve• Reduced customer packing specs from 147 to 52. • Developed a packing spec template for future use by customers. • Carried out a mini kaizen on the floor area to help combat wasted cardboard etc. • Communicated new specs to floor staff

Measurement consisted of:•Number of current packing specs (147).•€ being spent on cardboard and plastic.•Breakdown of costs per pallet e.g. Kraft finished pallet vs. mars finished pallet. •Volumes of cardboard being disposed of or wasted.

Difficulty with the number of packing specs need to reduce from 147 specs

• We compared volumes of pallets being dispatched versus actual cost of packaging the pallet. • We analysed the customer specs to evaluate their relevance and actual needs.

• Developed new Sop's for floor staff using the new packing specs• Monthly auditing of luas line area to ensure floor is being kept tidy and cardboard is not being wasted on site.

CELEBRATE

• We streamlined all the specs and were able to reduce them from 147 to 52 or 1 per site/ customer, we reduced the amount of cardboard in the specs

Validated€50K

Define Measure

ControlAnalyze

Green belt ~ Mislabelling storyboard ~ Robert Caldwell

Improve

Project defined by team;• Mislabelled lanes on coils• Mislabelled pallets• Impact on customer traceability• Possibility of losing significant business from mars due to complaints

Used root cause analysis and 5 why’s to find out the reason behind mislabellingWe discovered that due to a computer error that too many labels were being printed out and were being mixed up.

Involved slitting operatives to gain tribal knowledge of the system

• We reviewed who had access to end pallets• Implemented a new mini atms label to simplify things• ordered more aggressive labels

Mini Kaizen on area led to improvements

We developed a control plan to include:• Monthly auditing for first 3 months after project ended• Daily spot checks of pallets to ensure mini atms label is being used

We made a system change to atms to allow it to only print out finished pallet labels by 1 personThis reduced the number of labels at packaging

Due to new issues arising towards the end of 2007 we reviewed the project and made some more system changes, we now have a new bay for dispatch which again reduces chances of mislabelling

Mislabelling Complaints

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month

Valu

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2006

2007REVIEWED PROJECT

25K VALIDATED